TOHATSU MFS 25 Manuals

Manuals and User Guides for TOHATSU MFS 25. We have 2 TOHATSU MFS 25 manuals available for free PDF download: Service Manual, Owner's Manual

TOHATSU MFS 25 Service Manual (319 pages)

Brand: TOHATSU | Category: Outboard Motor | Size: 17.21 MB

1.Service Information

5
- Service Information
  
  4
  - Table of Contents
    5
- Identification (Engine Serial Number)
  
  12
- Securing of Work Safety
  
  12
  - Fire Prevention
    12
  - Ventilation
    12
  - Protection
    12
  - Genuine Parts
    12
  - Tools
    13
  - Recommendations on Service
    13
  - Cautions in Disassembling and Assembling Components
    14
- Tools and Instruments
  
  15
  - Test Propeller
    15
  - Measuring Instruments
    15
  - List of Special Tool
    16
- Pre-Delivery Inspection
  
  20
  - Steering Handle
    20
  - Gear Shift
    20
  - Engine Oil
    20
  - Gear Oil
    20
  - Fuel Line
    21
  - Rigging
    21
  - Inspection of PTT Unit
    21
  - Inspection of Gas Shock Absorber
    21
  - Inspection of Starting Switch and Stop Switch
    22
  - Cooling Water Check Port
    23
  - Idling
    23
  - Propeller Selection
    23
  - Trim Tab
    24
- Break-In Operation
  
  24
- Test Run
  
  25
- Checks after Test Run
  
  25
- Service Data
  
  27
- Outline Dimensions
  
  28
  - Engine Dimensions
    28
  - Transom Bolts
    29
- Fuel Injection System
  
  30
  - ECU Fuel Feed System
    30
- Engine Lubrication System Diagram
  
  31
- Cooling Water System Diagram
  
  32
- Specifications
  
  33
- Maintenance Data
  
  36
- Tightening Torque Data
  
  44
- Sealant Application Locations
  
  46
- Maintenance
  
  49
- Special Tool
  
  50
- Inspection Schedule
  
  51
- Inspection Items
  
  51
  - Inspection of Top Cowl
    52
  - Inspection of Fuel System Piping
    52
- Inspection Items
  
  52
4 4 Fuel System (Fuel Injection)

83
- Fuel System (Fuel Injection
  
  83
- ECU System
  
  83
- Special Tools
  
  84
- Piping Arrangement Diagram
  
  85
  - Fuel Hose, Vent Hose, Breather Hose, Cooling Water Hose
    85
- Parts Layout
  
  86
  - Fuel Pump, Fuel Rail, Vapor Separator
    87
    
    Intake Manifold
    89
    
    Magneto & ECU
    90
  - Electric Parts
    91
    
    Intake Manifold
    92
    
    Electric Parts
    92
- ECU System
  
  94
  - Sensors
    95
  - Actuators
    97
  - Control System (ECU)
    98
- (3) Fuel Injection Control 4-17
  
  99
- (2) Control System
  
  99
- (5) Control of Tachometer 4-18
  
  101
- (4) Control of Fuel Feed Pump (FFP) 4-18 7) Draining Fuel
  
  101
- Warning Buzzer and Lamp (LED), and Control of Engine Revolution Speed
  
  101
  - Locations of Warning Buzzer and Lamp (LED)
    101
  - Warning Notification, Abnormality and Action to be Taken
    101
- Ignition System
  
  102
  - Ignition and Combustion Orders
    103
  - Ignition Control
    103
  - Ignition Timing
    103
  - Ignition Timing Controls
    103
  - Operations
    103
  - Fuel Feed System
    104
- 4-12 1) Fuel Pump (Low Pressure Mechanical Pump)4-23
  
  105
- Components of Fuel Feed System
  
  105
  - Fuel Pump (Low Pressure Mechanical Pump)
    105
  - Vapor Separator
    105
  - Fuel Cooler
    106
  - Fuel Regulator
    106
- Outline of Fuel Injection System
  
  107
  - Air Intake System
    107
- Inspection Items
  
  108
  - Inspection of Fuel Supply System Piping
    108
  - Inspection of Filter
    108
  - Inspection of Fuel Pump
    110
    
    Measuring Fuel Pressure
    111
    
    Inspection of Fuel Regulator
    112
    
    Draining Fuel
    113
    
    Disassembly of Vapor Separator
    113
    
    Inspection of Vapor Separator
    114
  - Inspection of Idle Speed
    115
  - Inspection of ISC (Idle Speed Control)
    115
  - Reassembly of Vapor Separator
    115
    
    Power Unit
    117
    
    Special Tools
    118
    
    Parts Layout
    119
  - Recoil Starter
    120
    
    Magneto & ECU
    121
    
    Electric Parts
    122
    
    Fuel Pump, Fuel Rail, Vapor Separator
    124
  - Intake Manifold
    127
  - Cam Shaft & Oil Pump
    128
  - Cylinder Head
    129
  - Intake Valve & Exhaust Valve
    130
  - Cylinder
    131
  - Piston & Crankshaft
    132
  - Top Cowl
    133
- 4-16 1) Air Intake System
  
  108
- Inspection Items
  
  134
  - Inspection of Oil Pressure
    135
  - Inspection of Valve Clearance
    136
  - Removing Power Unit
    138
  - Removing Timing Belt and Pulley
    141
  - Inspection of Timing Belt
    142
  - Installation of Pulley and Timing Belt
    143
  - Removing Cylinder Head
    146
  - Inspection of Valve Spring
    148
  - Inspection of Valve
    149
  - Inspection of Valve Seat
    150
  - Correction of Valve Seat
    151
  - Inspection of Rocker Arm and Rocker Arm Shaft
    153
  - Inspection of Cam Shaft
    154
  - Inspection of Cylinder Head
    155
  - Inspection of Oil Pump
    156
  - Installation of Valves
    157
  - Installation of Cam Shaft
    158
  - Installation of Oil Pump
    159
  - Installation of Cylinder Head
    160
  - Disassembly of Cylinder Block
    161
  - Inspection of Piston Outer Diameter
    162
  - Inspection of Piston Ring Side Clearance
    163
  - Inspection of Piston Pins
    164
  - Inspection of Crankshaft
    165
  - Inspection of Crank Pin Oil Clearance
    166
  - Inspection of Crank Shaft Main Journal Oil Clearance
    167
  - Inner Diameter of Cylinder/Crank Case Bearing Holder (Inner Diameter Code)
    168
  - Assembling Piston and Connecting Rod
    169
  - Installation of Power Unit
    173
  - Removing Recoil Starter
    175
  - Inspection of Recoil Starter
    176
  - Installation of Recoil Starter
    177
6 Lower Unit

179
- Special Tools
  180
- Parts Layout
  
  182
  - Gear Case
    182
  - Drive System & Water Pump
    183
  - Shift
    185
- 1 Special Tools6-2
  
  182
- Inspection Items
  
  186
  - Draining Gear Oil
    186
  - Removing Propeller
    186
  - Removing Lower Unit
    187
  - Disassembly of Water Pump
    187
  - Inspection of Water Pump
    188
    
    Disassembly of Propeller Shaft Ass'y
    189
    
    Inspection of Propeller Shaft
    189
    
    Assembly of Propeller Shaft Ass'y
    189
  - Disassembly of Propeller Shaft Housing
    190
    
    Inspection of Propeller Shaft Housing
    191
    
    Assembly of Propeller Shaft Housing
    192
  - Removing Pump Case (Lower)
    193
  - Inspection of Cam Rod and Clutch Cam
    194
- 6-8
  
  195
  - Inspection of Drive Shaft
    195
  - Disassembly of Forward Gear (a Gear)
    195
  - Inspection of Pinion Gear (B Gear) and Forward Gear (a Gear)
    195
  - Assembly of Forward Gear (a Gear)
    195
  - Assembly of Drive Shaft
    196
  - Inspection of Gear Case
    197
  - Assembly of Lower Unit
    197
  - Installation of Pinion Gear (B Gear)
    198
  - Settling Pinion Gear (B Gear) Height
    199
  - Settling Forward Gear (a Gear) Backlash
    202
  - Reassembly of Pinion Gear Nut (B Gear Nut)
    205
  - Reassembly of Pump Case (Lower)
    206
  - Assembly of Water Pump
    206
  - Installation of Lower Unit
    208
7 Bracket

211
- Special Tools
  
  212
- PTT Wiring and Layout Diagram
  
  213
- Parts Layout
  
  214
  - Swivel Bracket (Mechanical Tilt)
    215
    
    Clamp Bracket & Reverse Lock
    216
    
    Bracket, PTT & Gas Assistant
    217
    
    Power Trim & Tilt
    219
    
    Tiller Handle
    220
    
    Bottom Cowl
    221
    
    Shift
    222
- Inspection Items
  
  224
  - Inspection of Throttle Cable
    224
  - Installation of Tiller Handle
    224
  - Adjustment of Co-Pilot Plate
    225
  - Removing Drive Shaft Housing
    226
  - Pulling out Upper Mount
    227
  - Inspection of Oil Strainer
    228
    
    Installation of Drive Shaft Housing Ass'y
    229
  - Removing Steering Shaft
    230
  - Installing Steering Shaft
    230
- 7-2
  
  231
8 Electrical System

247
- Special Tools
  
  248
- Electrical Component Layout
  
  249
  - Port Side View
    249
  - Bow Side View
    250
  - Starboard Side View
    251
  - Top View
    252
  - Tiller Handle Model
    253
- Parts Layout
  
  254
  - Magneto & ECU
    254
  - Electric Parts
    255
  - Electric Parts
    256
  - Starter Motor
    257
  - Fuel Pump, Fuel Rail, Vapor Separator
    258
- Ignition System, Ignition Control System
  
  260
  - Inspection of Ignition Sparks
    260
  - Inspection of Plug Cap
    260
  - Inspection of Ignition Coils
    261
  - Inspection of Alternator
    261
  - Inspection of Pulser Coil
    262
  - Inspection of Oil Pressure Switch
    262
  - Inspection of Water Temperature Sensor
    263
  - Inspection of Neutral Switch (Tiller Handle Model)
    263
  - Inspection of Start Switch (Tiller Handle Model)
    263
  - Inspection of Stop Switch
    264
- Fuel Control System
  
  265
- Starting System
  
  267
  - Inspection of Fuse
    267
  - Inspection of Starter Solenoid
    267
  - Disassembly of Starter Motor
    267
  - Inspection of Starter Motor Pinion
    268
  - Inspection of Armature
    268
  - Inspection of Brushes
    269
  - Inspection of Starter Motor Operation
    269
- Battery Charging System
  
  270
  - Inspection of Alternator
    270
  - Inspection of Rectifier
    270
- ECU Coupler
  
  271
9 Troubleshooting O

273
- Troubleshooting O K
  273
- Troubleshooting List
  
  274
- State 1 : Engine will Not Start or Is a Little Hard to Start.9-3
  
  275
- Power Unit
  
  275
  - Starting System
    275
  - Ignition System
    277
  - Fuel System
    279
- Engine Revolution Speed Fall Off.engine Stalls
  
  281
- State 2 : Full Throttle Engine Revolution Speed Is Low.
  
  282
  - Ignition System
    282
  - Fuel System
    283
  - Lubrication System
    284
  - Cooling System
    285
- In Low Speed Range
  
  286
- State 3 :Engine Rotation Is Unstable or Hunting Occurs
  
  287
  - Ignition System
    287
  - Fuel System
    288
- State 1 PTT will Not Operate
  
  289
- PTT Unit
  
  289
- State 2 PTT Is Not Capable of Sustaining Outboard Motor
  
  290
- 9-17
  
  290
- 3AC Diagnosis
  
  291
- State 2 : PTT Is Not Capable of Sustaining Outboard Motor.9-18
  
  291
- Set up
  
  291
- Hardware Connection
  
  294
  - Preparation
    294
- Position of ON/OFF Switch for Function Test and Running (Drop) Test
  
  295
- Operating Procedure
  
  296
  - Start up
    296
  - Menu Selection
    296
  - Setting Communication (COM) Port
    297
  - Monitoring ECU Data
    298
  - Monitoring History and Failure Code Retrieval
    299
  - Function Test
    300
  - Running Test (Drop Test)
    301
  - Air Purging from High Pressure Fuel Circuit
    302
  - Exit Diagnostic
    303
  - Explanation of Error Code
    303
- Accessories
  
  305
  - Remote Control Components
    306
    
    Remote Control Model
    306
  - Installation of Meters and Battery
    309
    
    Installation of Meters
    309
    
    Installation of Battery
    309
    
    Wiring Diagram of Remote and Control Meters
    310
    
    Operation
    311
    
    Warning Indication
    311
- Wiring Chart
  
  313
- Wiring Diagram
  
  314

TOHATSU MFS 25 Owner's Manual (45 pages)

Brand: TOHATSU | Category: Outboard Motor | Size: 2.49 MB

TOHATSU Categories

Outboard Motor Engine Water Pump Control Panel Diagnostic Equipment

More TOHATSU Manuals

TOHATSU MFS 25 Manuals

TOHATSU MFS 25 Service Manual (319 pages)

Table of Contents

1.Service Information

Service Information

Identification (Engine Serial Number)

Securing of Work Safety

Tools and Instruments

Pre-Delivery Inspection

Break-In Operation

Test Run

Checks after Test Run

Service Data

Outline Dimensions

Fuel Injection System

Engine Lubrication System Diagram

Cooling Water System Diagram

Specifications

Maintenance Data

Tightening Torque Data

Sealant Application Locations

Maintenance

Special Tool

Inspection Schedule

Inspection Items

Inspection Items

4 4 Fuel System (Fuel Injection)

Fuel System (Fuel Injection

ECU System

Special Tools

Piping Arrangement Diagram

Parts Layout

ECU System

(3) Fuel Injection Control 4-17

(2) Control System

(5) Control of Tachometer 4-18

(4) Control of Fuel Feed Pump (FFP) 4-18 7) Draining Fuel

Warning Buzzer and Lamp (LED), and Control of Engine Revolution Speed

Ignition System

4-12 1) Fuel Pump (Low Pressure Mechanical Pump)4-23

Components of Fuel Feed System

Outline of Fuel Injection System

Inspection Items

4-16 1) Air Intake System

Inspection Items

6 Lower Unit

Parts Layout

1 Special Tools6-2

Inspection Items

6-8

7 Bracket

Special Tools

PTT Wiring and Layout Diagram

Parts Layout

Inspection Items

7-2

8 Electrical System

Special Tools

Electrical Component Layout

Parts Layout

Ignition System, Ignition Control System

Fuel Control System

Starting System

Battery Charging System

ECU Coupler

9 Troubleshooting O

Troubleshooting List

State 1 : Engine will Not Start or Is a Little Hard to Start.9-3

Power Unit

Engine Revolution Speed Fall Off.engine Stalls

State 2 : Full Throttle Engine Revolution Speed Is Low.

In Low Speed Range

State 3 :Engine Rotation Is Unstable or Hunting Occurs

State 1 PTT will Not Operate

PTT Unit

State 2 PTT Is Not Capable of Sustaining Outboard Motor

9-17

3AC Diagnosis

State 2 : PTT Is Not Capable of Sustaining Outboard Motor.9-18

Set up